Systems and methods for providing non-corrosive surfaces

ABSTRACT

A system and method for providing a non-corrosive surface. In some embodiments, the system includes a concrete surface, a metal substrate coupled to the concrete surface, and a non-corrosive coating applied to the metal substrate. The non-corrosive coating includes a chemically inert polymer comprising EPDM rubber and an additive.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 63/334,060 (Attorney Docket No. 19069.16), which was filed on Apr.22, 2022, and is entitled SYSTEMS AND METHODS FOR PROVIDINGNON-CORROSIVE SURFACES; the entire disclosure of which is herebyincorporated by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to providing non-corrosive surfaces. Inparticular, the present invention relates to systems and methods forproviding non-corrosive, non-slip surfaces and surface overlays for usein exterior environments. At least some implementations include systemsand methods for providing non-corrosive surfaces directly to failedconcrete and/or to metal structures for walking traffic.

2. Background and Related Art

Concrete consists of a mixture of cement and water. As cement hardensand dries, excess mixing water in the cement evaporates. This causesshrinkage, which tends to result in cracks and deterioration in thecement.

Hardened concrete is also susceptible to corrosion, cracking, anddeterioration. This may be caused by corrosion of reinforcing steel andother embedded metals in the concrete, as well as by normal freezing andmelting cycles. Excess water in the concrete will freeze at temperaturesbelow 32° F., causing expansion of around 9% in all directions. When thecold temperatures rise to above freezing, the ice melts and runs deeperinto the cement structure which allows more water into the cracks frommelting ice and snow. The cycle repeats again and again with greatereffect until the surrounding concrete fractures and fails.

Salt and other chemical ice melts applied to the surface of the concretecan exacerbate the problem by also causing corrosion within the layersof the concrete. Salt and ice melts also unnaturally affect the freezingand melting process, which can cause additional issues.

Thus, while techniques currently exist for melting accumulated snow andice on concrete, challenges still exist, including damage and corrosionon concrete surfaces. Accordingly, it would be an improvement in the artto augment or even replace current techniques with other techniques.

SUMMARY OF THE INVENTION

The present invention relates to providing non-corrosive, non-slipsurfaces and surface overlays for use in exterior environments.

Implementation of the present invention takes place in association withpreserving concrete floors and structures. In some implementations, apolymer material is applied directly to the concrete surface, fillingany damage or corrosion in the concrete and providing a protective layeron the concrete. In a further implementation, a texture and/or granularmaterial (such as sand or other material) is included in the polymermaterial to provide a non-slick surface. In a further implementation, asystem for providing a non-corrosive surface includes a concretesurface, a metal substrate coupled to the concrete surface, and anon-corrosive coating applied to the metal substrate or metal structure.In some implementations, the non-corrosive coating includes a polymer,such as a chemically inert polymer having EPDM rubber and a granularadditive, crystalline additive, glass fibers, or other additive. In someimplementations, a heating element or system is coupled to the metalsubstrate.

While the methods and processes of the present invention have proven tobe particularly useful in the area of providing non-corrosive surfacesfor exterior concrete structures such as stairs, those skilled in theart can appreciate that the methods and processes can be used in avariety of different applications and in a variety of different areas ofmanufacture to yield non-corrosive, non-slip surfaces for variousexterior surfaces including sidewalks, porches, patios, driveways,parking lots, landscaping, swimming pools, and other structures orsurfaces.

These and other features and advantages of the present invention will beset forth or will become more fully apparent in the description thatfollows and in the appended claims. The features and advantages may berealized and obtained by means of the instruments and combinationsparticularly pointed out in the appended claims. Furthermore, thefeatures and advantages of the invention may be learned by the practiceof the invention or will be obvious from the description, as set forthhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the manner in which the above recited and other featuresand advantages of the present invention are obtained, a more particulardescription of the invention will be rendered by reference to specificembodiments thereof, which are illustrated in the appended drawings.Understanding that the drawings depict only typical embodiments of thepresent invention and are not, therefore, to be considered as limitingthe scope of the invention, the present invention will be described andexplained with additional specificity and detail through the use of theaccompanying drawings in which:

FIG. 1 illustrates a representative cement staircase that provides asuitable operating environment for use of at least some embodiments ofthe present invention;

FIG. 2 illustrates a representative cement porch and staircase thatprovides a suitable operating environment for use of at least someembodiments of the present invention;

FIG. 3 illustrates another representative cement surface that provides asuitable operating environment for use of at least some embodiments ofthe present invention;

FIG. 4 illustrates a representative non-corrosive composition used inconnection with a representative cement staircase in accordance withcertain embodiments of the present invention;

FIG. 5 is a perspective view of a non-corrosive composition used inconnection with a cement structure in accordance with some embodiments;

FIG. 6 is a top view of a surface in accordance with certain embodimentsof the present invention;

FIG. 7 is a perspective view of a surface treated with a non-corrosivecomposition in accordance with some embodiments;

FIG. 8 is a perspective view of a sidewalk ramp in accordance with someembodiments;

FIG. 9 is a perspective view of a porch and staircase in accordance withsome embodiments;

FIG. 10 is a perspective view of a sidewalk, porch, and stairs inaccordance with certain embodiments of the present invention;

FIG. 11 is a perspective view of a porch and staircase in accordancewith certain embodiments;

FIG. 12 is a perspective view of a porch surface in accordance with someembodiments;

FIG. 13 is a rear perspective view of a metal substrate formed into asidewalk surface in accordance with some embodiments;

FIG. 14 is front perspective view of the metal substrate of FIG. 13 ;

FIG. 15 is a front perspective view of the metal substrate of FIG. 13having a non-corrosive coating applied thereto in accordance withcertain embodiments;

FIG. 16 is a rear perspective view of a representative metal substrateformed into a staircase in accordance with some embodiments;

FIG. 17 is a side perspective view of the staircase of FIG. 16 ;

FIG. 18 is a front perspective view of the staircase of FIG. 16 ;

FIG. 19 is a perspective view of a representative staircase and landingin accordance with some embodiments of the present invention;

FIG. 20 is a plan diagram of one embodiment of a system in accordancewith the present invention;

FIG. 21 is a perspective side view of a representative embodiment of asystem in accordance with the present invention;

FIG. 22 is a perspective view of a representative embodiment of a systemincluding a porch, landing surface, and stairs;

FIG. 23 is a perspective view of one embodiment of stairs and a lateralsupport structure;

FIG. 24 is a perspective view of stairs between two sidewalls inaccordance with some embodiments;

FIG. 25 is a bottom view of stairs coupled to a sidewall in accordancewith certain embodiments;

FIG. 26 is a perspective view of representative embodiment of a systemhaving stairs and a banister; and

FIG. 27 is a side perspective view of the representative embodiment ofFIG. 26 , depicting an exposed sidewall.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to systems and methods for providingnon-corrosive surfaces and surface overlays. Embodiments of the presentinvention include non-corrosive, non-slip surfaces and/or surfaceoverlays to preserve and protect underlying concrete surfaces.

Embodiments of the present invention take place in association withpreserving concrete floors and structures. In some embodiments, apolymer material is applied to the concrete surface, filling any damageor corrosion in the concrete and providing a protective layer on theconcrete. In a further embodiment, a texture and/or granular material(such as sand or other material) is included in the polymer material toprovide a non-slick surface. In a further embodiments, a system forproviding a non-corrosive surface includes a concrete surface, a metalsubstrate coupled to the concrete surface, and a non-corrosive coatingapplied to the metal substrate. In some embodiments, the non-corrosivecoating includes a polymer, such as a chemically inert polymer havingEPDM rubber and a granular additive, crystalline additive, glass fibers,or other additive. In certain embodiments, a heating element or systemis coupled to the metal substrate. FIGS. 1-3 illustrate various examplesof concrete structures 100 having surfaces that have corroded anddeteriorated over time. As shown in FIGS. 1-2 , some existing concretestructures 100 include a staircase and/or landing or porch area. Asshown, concrete structure 100 includes various concrete surfaces 106that have corroded and deteriorated over time. Corrosion 102 can bevisible, for example, on the landing area 112, tread surfaces 108,risers 110, and side wall 114 of a stair structure 100, as well as on asurrounding concrete floor surface 106. Referring now to FIG. 3 ,concrete surface 106 includes a cement pad, curb, or other surface. Insome embodiments, concrete surface 106 includes a liner for a saltwaterpool or other structure, for example. Corrosion 102 includes cracks orgaps 104 that extend in various directions across the surface 106 and/oredges 116 of the concrete structure 100.

In some embodiments, a system for providing a non-corrosive surface maybe applied to such corroded concrete surfaces to protect and preservethe underlying concrete and to create a finished aesthetic surface thatappears new.

Referring now to FIGS. 4-5 , in some embodiments, a system 400 forproviding a non-corrosive surface includes a non-corrosive material orcoating 404 that is applied directly to concrete surface 106. As shown,in some embodiments, the non-corrosive material or coating 404 providesa patch to repair an area of corrosion 102 on the surface 106. In otherembodiments, the system 400 for providing a non-corrosive surfaceincludes a non-corrosive material or coating 404 that is applied to ametal substrate, such as aluminum, steel, copper, iron, or an alloythereof. In one embodiment, the metal substrate includes an atmosphericcorrosion resistant steel. In some embodiments, the metal substrateincludes one or more segments or is monolithically formed as a singleunit. In these and other embodiments, the metal substrate can beoverlaid onto a concrete surface 106 as discussed in more detail withreference to FIGS. 8-12 below, or can be used independently.

In these and other embodiments, the non-corrosive material or coating404 includes a chemically inert polymer and a granular or crystallineadditive. In one embodiment, the non-corrosive material or coating 404includes about fifty percent (50%) polymer and about fifty percent (50%)additive by volume. In other embodiments, the polymer occupies more than50% by volume of the non-corrosive material or coating 404.

Advantageously, in some embodiments, the non-corrosive material orcoating 404 is inert to salt as well as to all forms of ice meltingchemicals. In some embodiments, the non-corrosive material or coating404 is inert to natural elements of the earth. Thus, in someembodiments, once the system 400 for providing a non-corrosive surfaceis installed, salt and ice melting chemicals can be applied with noadditional damage resulting to the underlying concrete surface 106 or tothe overlay.

In some embodiments, the polymer and resulting non-corrosive material orcoating 404 exhibits excellent heat, ozone/weathering, aging andabrasion resistance. In some embodiments, the polymer and resultingnon-corrosive material or coating 404 further exhibits excellentelectrical insulation, compression set, and low temperature properties.For example, in some embodiments, the polymer is stable in environmentswith temperatures between about −45° F. and above 170° F. In certainembodiments, the polymer includes ethylene propylene diene monomer(“EPDM”) or liquid rubber, thermoplastic polyolefin (“TPO”), tar,thermoplastic vulcanizates (TPVs), or the like.

Some embodiments of the polymer are very flexible and stretchable tofacilitate application of the non-corrosive material or coating 404 tosurfaces having surface imperfections. In one embodiment, the polymerincludes EPDM rubber and is stretchable of up to five hundred percent(500%) by mass.

In these and other embodiments, the non-corrosive material or coating404 includes an adhesion and bonding strength relative to concretesurfaces such as sidewalks, porches, stairs, curbs, and the like. Insome embodiments, the non-corrosive material or coating 404 includesadhesion and bonding strength relative to metal surfaces such asaluminum, steel, copper, and alloys thereof. In these and otherembodiments, the non-corrosive material or coating 404 is long-lastingin all weather conditions.

In certain embodiments, the non-corrosive material or coating 404 sealsa surface such that it is rendered impenetrable to moisture. Forexample, as depicted in FIGS. 4-5 , some embodiments of thenon-corrosive material or coating 404 is applied to seal a surface 106and even fill in cracks or gaps 104 between adjacent surface areas. Insome embodiments, one or more fillers, such as foam, dirt, wood, rock,gravel, plaster of paris, or the like, are deposited to fill surfacevoids before the non-corrosive material or coating 404 is applied.

Referring now to FIGS. 6-7 , some embodiments of the non-corrosivematerial or coating 404 further includes a granular or crystallineadditive. In some embodiments, inclusion of the additive provides achange in property, such as increasing the stiffness of thenon-corrosive material or coating 404 and/or providing a non-slicksurface in the non-corrosive material or coating 404. In certainembodiments, the additive facilitates application of the non-corrosivematerial or coating 404 to existing surfaces 106. In some embodiments,the additive increases the co-efficient of traction of the non-corrosivematerial or coating 404 to facilitate safety where the non-corrosivematerial or coating 404 is designed to be walked on or traveled over. Insome embodiments, the additive includes a natural sand, blow sand,silica sand, or other suitable granular or crystalline material.

In some embodiments, the crystalline additive improves the appearance ofthe surface 106 after the non-corrosive material or coating 404 isapplied. In certain embodiments, the additive and/or the polymerincludes one or more colors to vary and/or improve the appearance of thenon-corrosive material or coating 404 and the surface 106 to which it isapplied.

In some embodiments, the non-corrosive material or coating 404 isapplied to the surface 106 with a trowel, roller, screed, paint brush,sprayer, or other suitable tool. In some embodiments, the non-corrosivematerial or coating 404 is sprayed on to a surface 106. In someembodiments, the tool used to apply the non-corrosive material orcoating 404 includes one or more features configured to form a texture600 or pattern in the non-corrosive material or coating 404. In theseand other embodiments, various techniques for using the application toolcreate the texture 600 or pattern in the non-corrosive material orcoating 404. In some embodiments, the texture 600 or pattern provides anon-slip surface. In some embodiments, the texture 600 or patterndisguises corrosion 102 or other imperfections in the surface 106,and/or improve the appearance, strength, and/or life of the surface 106.

Referring now to FIGS. 8-12 , in some embodiments, a system 400 forproviding a non-corrosive surface includes a concrete surface 106, ametal substrate or surface overlay 800 coupled to the concrete surface106, and a non-corrosive material or coating 404 applied to the surfaceoverlay 800. As discussed above, in some embodiments, the surfaceoverlay 800 is formed as multiple segments or can be monolithicallyformed as a single unit.

As shown in FIG. 8 , in one embodiment, the concrete surface 106includes a sidewalk ramp. In some embodiments, one or more surfaceoverlays 800 are coupled to the concrete surface 106 via one or morefasteners, adhesives, and/or couplers. In some embodiments, the surfaceoverlays 800 are aligned such that an outside edge of one surfaceoverlay 800 contacts an outside edge of an adjacent surface overlay 800.In some embodiments, adjacent surface overlays 800 is coupled to oneanother surface overlay. In other embodiments, adjacent surface overlays800 are spaced apart from one another by a defined distance, or in anyother desired configuration or manner.

Referring now to FIGS. 9-11 , in some embodiments, the concrete surface106 includes a concrete staircase or other concrete structure. In someembodiments, the concrete surface 106 includes one or more of a landingarea 112, a tread surface 108, a riser surface 110, a side wall surface114, a floor surface 118, or other suitable concrete structure orsurface 106. In some embodiments, the system 400 for providing anon-corrosive surface includes surface overlays 800 configured tooverlay each of the concrete surfaces 106. Adjacent surface overlays 800are coupled together via one or more fasteners such as screws, nails,rivets, or the like. In some embodiments, an adhesive such as very highbond (“VHB”) tape is used to couple adjacent surface overlays 800together. In some embodiments, the surface overlays 800 are coupled tothe concrete surfaces 106 by way of one or more fastening mechanismsknown to those in the art.

In some embodiments, the non-corrosive material or coating 404 isapplied to the surface overlay 800 prior to positioning the surfaceoverlay 800 on the concrete surface 106. In other embodiments, thenon-corrosive material or coating 404 is applied to the surface overlay800 after it is coupled to the concrete surface 106.

Referring now to FIG. 10 , in some embodiments of a system 400 forproviding a non-corrosive surface, one or more fillers 402 are depositedinto cracks and gaps 104 between adjacent concrete surfaces 106 beforethe non-corrosive material or coating 404 is applied to seal the space.In other embodiments, the non-corrosive material or coating 404 isdeposited into the cracks and gaps 104 to act as filler as well as asealant. In certain embodiments, the non-corrosive material or coating404 fills in cracks and gaps 104 in failed concrete up to a half inchwide.

Referring now to FIG. 11 , in some embodiments, the surface overlay 800is formed to include a size and shape substantially matching theunderlying concrete surface 106. In other embodiments, the surfaceoverlay 800 includes a size and shape larger than the underlyingconcrete surface 106 to create a desired aesthetic appearance.

Certain embodiments include one or more heating elements coupled to thesurface overlay 800 to prevent freezing, melt ice and snow, and improvesurface traction. In some embodiments, the heating element includes, forexample, an electric, radiant, or hydronic heating element coupled to ordisposed beneath or adjacent to the surface overlay 800. In someembodiments, the heating element is coupled to a power source. In someembodiments, the power source is a solar power source.

In one embodiment, for example, one or more heating elements are coupledto or disposed beneath each surface overlay 800 segment. In otherembodiments, a series or array of heating elements are coupled to ordisposed beneath each surface overlay 800. In some embodiments, theheating elements are coupled to or disposed at predetermined distancesbetween surface overlays 800 or are positioned adjacent to one or moresurface overlays 800.

In some embodiments, the heating element is configured to maintain thetemperature of the surface overlay 800 above freezing (above 32° F.).For example, in some embodiments, the heating element is configured tomaintain the surface overlay 800 above freezing. In some embodiments,the heating element is configured to maintain the surface overlay up toabout 10° F. above freezing. In some embodiments, the heating element isconfigured to maintain the surface overlay more than 10° F. abovefreezing.

Referring now to FIGS. 12-15 , some embodiments of a system 400 forproviding a non-corrosive surface include a flat concrete area such as aporch, landing area 112, or floor surface. In other embodiments, thesystem 400 for providing a non-corrosive surface includes a flatconcrete area such as a sidewalk, ramp, driveway, or parking area. Insuch embodiments, the system 400 for providing a non-corrosive surfaceincludes high compression strength sufficient to support the weight ofautomobiles and other vehicles.

In some embodiments, the metal substrate or surface overlay 800 includesmultiple segments 800 a, 800 b coupled together. In one embodiment, asshown in FIGS. 13-15 , one segment 800 a is aligned with an adjacentsegment 800 b along its horizontal edge. In some embodiments, the system400 for providing a non-corrosive surface includes a frame 802 or railsto facilitate segment 800 a, 800 b alignment. In some embodiments, eachsegment 800 a, 800 b is coupled to the frame 802 and/or to an adjacentsegment 800 a, 800 b via one or more fasteners 1400 a, 1400 b. In someembodiments, fasteners 1400 include, for example, one or more screws,nails, rivets, seams, crimps, welds, or the like. In certainembodiments, a segment 800 a is attached to the frame 802 and/or to anadjacent segment 800 b via an adhesive.

Referring now to FIG. 15 , in some embodiments, multiple segments 800 a,800 b are attached to the frame 802 prior to application of thenon-corrosive material or coating 404. In this manner, in someembodiments, the non-corrosive material or coating 404 is applied toextend over and/or seal a gap 804 between adjacent segments 800 a, 800b. Similarly, the non-corrosive material or coating 404 is applied toextend over exposed portions of fasteners 1400 a, 1400 b used to couplethe segments 800 a, 800 b to each other and/or to the frame 802.

Referring now to FIGS. 16-19 , in some embodiments, a system 400 forproviding a non-corrosive surface includes providing a metal substratestructure 1600 that may be used independently from a concretesubstructure. In one embodiment, as shown in FIG. 16 for example, thesubstrate structure 1600 includes aluminum or another suitable metalthat may be bent or otherwise formed to include a set of stairs and alanding area 112. As shown, the substrate structure 1600 includes one ormore attachment surfaces 1610 such as a top edge 1602 and side edges1604 extending from a rear periphery of the substrate structure 1600.

In some embodiments, the top edge 1602 extends in a transverse directionrelative to the landing area 112. Similarly, one or more of the sideedges 1604 extends in a transverse direction relative to the side walls114 of the substrate structure 1600. An adhesive and/or fastener isapplied to the top edge 1602 and/or side edges 1604 to secure thesubstrate structure 1600 to an adjacent structure. As illustrated inFIG. 19 , in some embodiments, the attachment surfaces 1610 are disposedto correspond to an adjacent wall of the existing structure such thatthe substrate structure 1600 is secured to the existing structure.

With reference to FIGS. 17-18 , in some embodiments, a base edge 1608extends in a transverse direction from a front periphery of thesubstrate structure 1600 to facilitate securing the substrate structure1600 to a ground level. In some embodiments, one or more lateral edges1606 extend in a transverse direction from a base of the side wall 114to further secure the substrate structure 1600 to the ground level.

Referring now to FIGS. 20-22 , some embodiments of the substratestructure 1600 include multiple surfaces 106 that interlock or areotherwise coupled together. For example, as shown in the diagram 2000 ofFIG. 20 , some embodiments of the substrate structure 1600 includeinterlocking steps 2006 having a tread surface 108 formed to extend in atransverse direction into a riser surface 110.

In some embodiments, the interlocking steps 2006 a, 2006 b is formedfrom aluminum, steel, Corten steel, copper, or an alloy thereof. Someembodiments of the interlocking steps 2006 a, 2006 b include multipletread surfaces 108 formed to extend into riser surfaces 110 on eachlateral side. In some embodiments, the riser surface 110 extendssubstantially perpendicularly relative to the tread surface 108. Asillustrated in FIGS. 20-21 , in some embodiments, a base edge 2002 ofone riser surface 110 includes an interlocking lip 2004 configured toengage a base edge 2002 of the other riser surface 110. In someembodiments, the interlocking lip 2004 extends at an angle of between30° and 60° relative to the base edge 2002. In one embodiment, theinterlocking lip 2004 extends at a 45° angle relative to the base edge2002. In this manner, some embodiments provide a series of interlockingsteps 2006 a, 2006 b where an interlocking lip 2004 of one step 2006 aengages a base edge 2002 of another step 2006 b.

In some embodiments of a system 400 for providing a non-corrosivesurface, the series of interlocking steps 2006 a, 2006 b are implementedas an overlay to protect an existing concrete structure 100. In otherembodiments, the series of interlocking steps 2006 a, 2006 b areinstalled independently without an underlying concrete substructure. Asshown in FIG. 22 , in one embodiment, the system 400 for providing anon-corrosive surface is installed for independent use by securing theseries of interlocking steps 2006 a, 2006 b against an existingstructure, such as a house. In some embodiments, this can stabilize thesystem 400 without requiring a base structure. Some embodiments of theseries of interlocking steps 2006 a, 2006 b includes fasteners 1400and/or adhesives to further secure a first interlocking step 2006 a to asecond interlocking step 2006 b.

Referring now to FIGS. 23-27 , in some embodiments, the system 400utilizes a foundation structure 2300 to further stabilize a substratestructure 1600 such as a series of interlocking steps 2006 a, 2006 b forindependent use. In this manner, in certain embodiments, the series ofinterlocking steps 2006 a, 2006 b are implemented without a basesubstructure. As shown, in some embodiments, the foundation structure2300 includes one or more sidewalls 2302 a, 2302 b secured to theinterlocking steps 2006. In one embodiment, the foundation structure2300 is coupled to one or more attachment surfaces 1610 extending fromthe interlocking steps 2006 a, 2006 b.

In some embodiments, the foundation structure 2300 further includes oneor more angle supports 2304 disposed beneath the interlocking steps 2006a, 2006 b. The angle supports 2304 conform to a size and shape of aportion of each step 2006 to provide stability thereto. As shown in FIG.25 , in some embodiments, the angle supports 2304 are secured to thefoundation structure 2300 via one or more attachment devices ofmechanisms such as bolts, screws, nails, rivets, or the like.

Referring to FIGS. 26-27 , in some embodiments, a method for providing anon-corrosive surface in accordance with some embodiments of theinvention include providing a substrate structure 1600 including a metalsuch as aluminum, steel, copper, iron, and/or alloys thereof. In someembodiments, the substrate structure 1600 is overlaid onto an existingcement or concrete surface 106, such as stairs, a porch area, a landingarea, a floor, a pool, pool stairs, a hot tub, a wall, a parking lot, orother structure. In other embodiments, the substrate structure 1600 isused independently or overlaid onto a non-cement structure such as avehicle or equipment surface. In some embodiments, the method includesproviding one or more heating elements disposed adjacent to thesubstrate structure 1600 to maintain the substrate structure 1600 attemperatures above freezing.

In some embodiments, the substrate structure 1600 is coupled to theexisting structure and a non-corrosive material or coating 404 isapplied thereto. In some embodiments, a filler 402 is used to fill voidsin the existing concrete surface 106 prior to applying the non-corrosivematerial and/or coating 404. In other embodiments, the non-corrosivematerial or coating 404 is used as the filler 402.

In some embodiments, the non-corrosive material or coating 404 includesa chemically inert polymer and a additive, such as a granular,crystalline, or other additive. In some embodiments, the chemicallyinert polymer includes EPDM rubber and the additive includes sand. Insome embodiments, the non-corrosive material or coating 404 includesabout 10-60% by volume of the chemically inert polymer. Applying thenon-corrosive material or coating 404 to the substrate structure 1600includes applying a texture 600 or pattern to the non-corrosive materialor coating 404 to provide a non-slip surface.

Thus, as discussed herein, embodiments of the present invention providesa non-corrosive, non-slip surface. The present invention may be embodiedin other specific forms without departing from its spirit or essentialcharacteristics. The described embodiments are to be considered in allrespects only as illustrative and not restrictive. The scope of theinvention is, therefore, indicated by the appended claims rather than bythe foregoing description. All changes that come within the meaning andrange of equivalency of the claims are to be embraced within theirscope.

What is claimed is:
 1. A system for providing a non-corrosive surface,comprising: a concrete surface; a metal substrate coupled to theconcrete surface; and a non-corrosive coating applied directly to atleast one of (i) the concrete surface and (ii) the metal substrate, thenon-corrosive coating comprising: a chemically inert polymer; and anadditive.
 2. The system of claim 1, wherein the chemically inert polymercomprises EPDM rubber.
 3. The system of claim 1, wherein thenon-corrosive coating comprises about 50% by volume of the additive. 4.The system of claim 1, further comprising a heating element electricallycoupled to the metal substrate.